Wire harness and method for manufacturing thereof

ABSTRACT

A wire harness includes a functional exterior component, at least one electric wire, and at least one thread. The functional exterior component is shaped into a sheet. The electric wire is disposed on one main surface of the functional exterior component. With the thread the electric wire is sewn on the functional exterior component.

TECHNICAL FIELD

This invention relates to a technology for attaching electric wires toan exterior component in a wire harness for vehicle.

BACKGROUND ART

Patent Document 1 discloses a technology, when a sheet-shaped exteriorcomponent is attached to electric wires, for positioning the exteriorcomponent with respect to the electric wires by winding a tape aroundeach terminal portion of the exterior component and the electric wiresprotruding from the terminal portion.

PRIOR ART DOCUMENT Patent Document

-   Patent Document 1: Japanese Patent Application Laid-Open No.    2015-72798

SUMMARY Problem to be Solved by the Invention

Here, various components having at least one function of soundproofing(sound-damping, sound absorption, sound insulation, etc.), protection(abrasion resistance, tensile resistance, etc.), heat radiation,shielding, waterproofing, etc. are used as the exterior components inthe wire harness for vehicle. If the various components have differentstructures for attaching these various components to electric wires, thenumber of process types commensurately increase.

The object of the present invention is to provide a structure applicablein common to various exterior components upon attachment to electricwires.

Means to Solve the Problem

To solve the problem, a wire harness according to a first aspectincludes: a functional exterior component shaped into a sheet; at leastone electric wire disposed on one main surface of the functionalexterior component; and at least one thread for sewing the electric wireon the functional exterior component.

A wire harness according to a second aspect is the wire harnessaccording to the first aspect, and the functional exterior componentincludes a soundproof component with soundproofing properties.

A wire harness according to a third aspect is the wire harness accordingto the first or the second aspect, and the functional exterior componentincludes a shielding component capable of shielding the electric wire.

A wire harness according to a fourth aspect is the wire harnessaccording to one of the first aspect to the third aspect, and thefunctional exterior component includes a protective component capable ofprotecting the electric wire from abrasion, the protective componenthaving abrasion resistance.

A wire harness according to a fifth aspect is the wire harness accordingto one of the first aspect to the fourth aspect, and the functionalexterior component includes a heat radiating component capable ofradiating heat of the electric wire.

A wire harness according to a sixth aspect is the wire harness accordingto the fifth aspect, and a high emission ratio portion is formed on asurface of the heat radiating component, the high emission ratio portionbeing higher in emission ratio than an inner portion of the heatradiating component.

A wire harness according to a seventh aspect is the wire harnessaccording to one of the first aspect to the sixth aspect, and thefunctional exterior component functions as a tension member subjected totensile force applied to the electric wire.

A wire harness according to an eighth aspect is the wire harnessaccording to one of the first aspect to the seventh aspect, and in thefunctional exterior component, a tensile strength in a direction alongan extension direction of the electric wire is higher than a tensilestrength in a direction orthogonal to the direction.

A wire harness according to a ninth aspect is the wire harness accordingto one of the first aspect to the eighth aspect, and the functionalexterior component is water-proofed, and covers the electric wire and aportion on which the electric wire is sewn.

A wire harness according to a tenth aspect is the wire harness accordingto one of the first aspect to the ninth aspect, and a connector providedat an end of the electric wire is sewn on the functional exteriorcomponent.

A wire harness according to an eleventh aspect is the wire harnessaccording to one of the first aspect to the tenth aspect, and afastening component for fastening the electric wire to a mounting objectis sewn on the functional exterior component.

A wire harness according to a twelfth aspect is the wire harnessaccording to one of the first aspect to the eleventh aspect, and theelectric wire is sewn with the thread that is a single thread.

A wire harness according to a thirteenth aspect is the wire harnessaccording to one of the first aspect to the eleventh aspect, and theelectric wire is sewn with the at least one thread including an upperthread and a lower thread.

A method for manufacturing the wire harness according to a fourteenthaspect is a method for manufacturing the wire harness according to thetwelfth aspect, and includes the steps of: (a) inserting a needle intothe functional exterior component from another main surface of thefunctional exterior component, the needle having an eye through whichthe thread passes as an upper thread; (b) forming a loop from the upperthread that has passed through the one main surface; and (c) threadingthe electric wire through the loop as a lower thread.

A method for manufacturing the wire harness according to a fifteenthaspect is a method for manufacturing the wire harness according to thethirteenth aspect, and includes the steps of: (a) disposing the electricwire on the one main surface of the functional exterior component; and(b) sewing the upper thread and the lower thread on the functionalexterior component with the electric wire being sandwiched between oneof the upper thread and the lower thread and the one main surface of thefunctional exterior component.

Effects of the Invention

According to the first to the fifteenth aspects, the electric wire issewn on the exterior component with the thread. This structure can beapplied in common to various exterior components upon attachment toelectric wires.

Particularly, according to the second aspect, a soundproof structure canbe easily given.

Particularly, according to the third aspect, the electric wire can beeasily shielded.

Particularly, according to the fourth aspect, the electric wire can beeasily protected.

Particularly, according to the fifth aspect, heat of the electric wirecan be easily radiated.

Particularly, according to the sixth aspect, the heat radiation effectcan be enhanced.

Particularly, according to the seventh aspect, the electric wire ishardly damaged even with application of the tensile force to the wireharness.

Particularly, according to the eighth aspect, the functional exteriorcomponent hardly ruptures even with application of the tensile force tothe wire harness.

Particularly, according to the ninth aspect, the electric wire can beeasily waterproofed.

Particularly, according to the tenth aspect, the connector can be easilypositioned.

Particularly, according to the eleventh aspect, the fastening componentcan be easily attached.

Particularly, according to the twelfth aspect, the electric wire can besewn with the minimal number of threads.

Particularly, according to the thirteenth aspect, the electric wire doesnot have to be used as an upper thread or a lower thread. Thus, anelectric wire with difficulties in being applied as the upper thread orthe lower thread, for example, a thick wire can be easily sewn.

Particularly, according to the fourteenth aspect, the electric wire canbe sewn on the functional exterior component. Since a sewing machine isavailable herein, the wire harness can be easily manufactured.

Particularly, according to the fifteenth aspect, the electric wire canbe sewn on the functional exterior component. Since a sewing machine isavailable herein, the wire harness can be easily manufactured.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a perspective view of a wire harness according toEmbodiment 1.

FIG. 2 illustrates a schematic cross-sectional view of the wire harnessaccording to Embodiment 1.

FIG. 3 illustrates steps for manufacturing the wire harness according toEmbodiment 1.

FIG. 4 illustrates the steps for manufacturing the wire harnessaccording to Embodiment 1.

FIG. 5 illustrates the steps for manufacturing the wire harnessaccording to Embodiment 1.

FIG. 6 illustrates the steps for manufacturing the wire harnessaccording to Embodiment 1.

FIG. 7 illustrates a schematic perspective view of a wire harnessaccording to Embodiment 2.

FIG. 8 illustrates a partial enlarged plan view of a wire harnessaccording to Embodiment 3.

FIG. 9 illustrates a schematic cross-sectional view of a wire harnessaccording to Embodiment 4.

FIG. 10 illustrates a schematic cross-sectional view of a wire harnessaccording to Embodiment 5.

FIG. 11 illustrates a schematic plan view of a wire harness according toEmbodiment 6.

FIG. 12 illustrates a schematic cross-sectional view of the wire harnesscut along an XII-XII line in FIG. 11.

FIG. 13 illustrates steps for manufacturing the wire harness accordingto Embodiment 6.

FIG. 14 illustrates a schematic plan view of a modification of the wireharness according to Embodiment 6.

FIG. 15 illustrates a schematic cross-sectional view of the wire harnesscut along an XV-XV line in FIG. 14.

FIG. 16 illustrates a schematic cross-sectional view of a modificationof a functional exterior component.

FIG. 17 illustrates a schematic plan view of another modification of thefunctional exterior component.

FIG. 18 illustrates a schematic perspective view of another modificationof the wire harness according to Embodiment 6.

DESCRIPTION OF EMBODIMENTS Embodiment 1

A wire harness according to Embodiment 1 will be described. FIG. 1illustrates a perspective view of a wire harness 10 according toEmbodiment 1. FIG. 2 illustrates a schematic cross-sectional view of thewire harness 10 according to Embodiment 1. Note that FIG. 2 is across-sectional view of the wire harness 10 cut in a plane along anextension direction of electric wires 12.

The wire harness 10 is used as wiring for electrically connectingvarious electrical devices mounted on, for example, a vehicle. The wireharness 10 is routed around, for example, an installment panel, a roof,and a door in the vehicle. Specifically, the wire harness 10 includes afunctional exterior component 30, the electric wires 12, and threads 40.The wire harness 10 additionally includes connectors 20 and fasteningcomponents 50.

The functional exterior component 30 is shaped into a sheet. In theexample illustrated in FIG. 1, the functional exterior component 30 isshaped into a rectangular sheet. The shape of the functional exteriorcomponent 30 is not limited to the aforementioned shape, but can beappropriately changed according to, for example, the placement of theelectric wires 12. The functional exterior component 30 is a componentin which the electric wires 12 are covered. The functional exteriorcomponent 30 is a component having at least one of functions ofsoundproofing (sound-damping, sound absorption, sound insulation, etc.),protection (abrasion resistance, tensile resistance, penetrationresistance, etc.), heat radiation, shielding, waterproofing, etc. forthe electric wires 12. An appropriate one of the functions of thefunctional exterior component 30 is selected according to, for example,the properties of the electric wires 12 and an environment of a portionon which the electric wires 12 are disposed. Since the electric wires 12are disposed in a portion that may rub against the surroundingcomponents, an example where the functional exterior component 30 is aprotective sheet (protective component) with abrasion resistance will bedescribed.

The protective sheet is formed of a sheet material such as polyvinylchloride (PVC), polypropylene (PP), or a nonwoven fabric. When theprotective sheet is formed of a nonwoven fabric, the protective sheetmay be, for example, hot-pressed. Consequently, the protective sheet canbe hardened. The abrasion resistance of the protective sheet may beobtained from physical properties of its structure or from physicalproperties of the raw material. Although the protective sheet is formedflat in the example illustrated in FIG. 1, application of a structurehaving protrusions and depressions on an external surface of thisprotective sheet will be able to increase the abrasion resistance of theprotective sheet. For another example, application of a structure withthe nonwoven fabric hot-pressed will be able to harden the protectivesheet and increase the abrasion resistance. For another example,application of a hard raw material as a material for the protectivesheet will be able to increase the abrasion resistance.

The electric wires 12 are disposed on one main surface 31 a of thefunctional exterior component 30. The number of the electric wires 12may be at least one. Here, the number of the electric wires 12 is two ormore (two in the example illustrated in FIG. 1). The description hereinis given by applying, as the electric wires 12, insulated electric wires12 each including a core wire 14 and an insulating coating 16 forcoating the core wire 14 (see FIG. 9). The core wire 14 is made of aconductive material such as copper or aluminum. The core wire 14 may bea solid wire or a stranded wire. The insulating coating 16 may be formedby extrusion molding, for example, a resin around the core wire 14 or byapplying, for example, varnish around the core wire 14 and baking thevarnish. The core wires 14 that are bare may be used as the electricwires 12.

When a manufacturing method using, for example, a sewing machine isapplied, the electric wires 12 preferably have a high tensile strength,which will be described later in detail. The electric wires 12 arepreferably thin. In view of this, signal lines which are relatively thinare more suitable as the electric wires 12 than power lines which tendto be relatively thick.

The ends of the electric wires 12 are integrated with the connectors 20.While the wire harness 10 is disposed in a target portion in a vehicle,etc., the connectors 20 are connected to connectors of the variouselectrical devices mounted on the vehicle. Consequently, the wireharness 10 is used as the wiring for electrically connecting the variouselectrical devices mounted on the vehicle.

Here, the connectors 20 are also sewn on the functional exteriorcomponent 30. Connector housings 21 of the connectors 20 have holes 22or depressions, etc. through which the connector housings 21 are sewn onthe functional exterior component 30. The holes 22 or the depressionsmay be existing components formed on, for example, locking portions orcassette portions, or new dedicated components. It is not necessary tosew the connectors 20 on the functional exterior component 30. Here, theconnector 20 may or may not be fastened to the functional exteriorcomponent 30 with another means such as an adhesive tape or an adhesive.

As illustrated in FIG. 2, the connectors 20 are the connectors 20 ofinsulation-displacement type. Specifically, the connector housings 21each include a first component 23, and a second component 24 that can beincorporated into the first component 23. The first component 23 canhold an insulation-displacement contact 26 with aninsulation-displacement part 27 exposed outside. Theinsulation-displacement part 27 is included in theinsulation-displacement contact 26, and can be connected to theinsulated electric wires 12 with pressure. The first component 23 housesa partner joint 28 to be connected to a partner conductor, with thepartner conductor connectable. The partner joint 28 is included in theinsulation-displacement contact 26. The second component 24 is disposedopposite to a portion of the first component 23 for holding theinsulation-displacement part 27, and can press the insulated electricwires 12 toward the insulation-displacement part 27. The secondcomponent 24 presses the insulated electric wires 12 toward theinsulation-displacement part 27, while the insulated electric wires 12are located on the insulation-displacement part 27 in theinsulation-displacement contact 26 held by the first component 23without being peeled off. Consequently, a part of theinsulation-displacement part 27 breaks the insulation coating of theinsulated electric wires 12 to abut and be connected to the core wire14.

Here, all the two electric wires 12 are sewn on the functional exteriorcomponent 30 with the threads 40 in the example illustrated in FIG. 1.When the number of the electric wires 12 included in the wire harness 10is two or more, the electric wires 12 may include the electric wires 12that are not sewn on the functional exterior component 30.

The two electric wires 12 are connected to the same connectors 20 in theexample illustrated in FIG. 1. When the number of the electric wires 12included in the wire harness 10 is two or more, the electric wires 12may include the electric wires 12 that are connected to the differentconnectors 20.

The electric wires 12 are linearly disposed in the example illustratedin FIG. 1. The electric wires 12 may be curved. When the number of theelectric wires 12 included in the wire harness 10 is two or more, theelectric wires 12 linearly disposed and the electric wires 12 that arecurved may coexist. Here, the plurality of the electric wires 12 mayhave branches on the functional exterior component 30.

The electric wires 12 are disposed closer to the center of thefunctional exterior component 30 in a width direction in the exampleillustrated in FIG. 1. The route along which the electric wires 12 aredisposed with respect to the functional exterior component 30 is notlimited to the one described above. The electric wires 12 may bedisposed, for example, closer to the end of the functional exteriorcomponent 30 in the width direction. The electric wires 12 may, forexample, extend diagonally to the functional exterior component 30.

The electric wires 12 are sewn on the functional exterior component 30with the threads 40. The threads 40 are preferably components moreflexible than the electric wires 12. The thread 40 preferably has atensile strength higher than that of the electric wires 12. The thread40 may be made of a natural fiber or a chemical fiber. The thread 40 maybe a single yarn or a twisted yarn.

When the thread 40 may abut the surrounding components while beingincorporated into a vehicle, the thread 40 preferably has abrasionresistance as high as, for example, a fishing line made of nylon orpolyester etc.

As illustrated in FIG. 2, the one seamless thread 40 is applied as thethread 40 for sewing the one electric wire 12, and the electric wire 12is sewn in a plurality of positions along the extension direction of theelectric wire 12 with the single thread 40. While extending alonganother main surface 31 b of the functional exterior component 30, theone seamless thread 40 partly passes through the one main surface 31 aof the functional exterior component 30 to form a loop 85. Then, theelectric wire 12 is threaded through the loop 85, so that the electricwire 12 is sewn.

It is not necessary to sew the one electric wire 12 with the oneseamless thread 40. The thread 40 with which the electric wire 12 ispartly sewn in one position and which is then cut in both of the endsmay exist in a plurality of portions along the extension direction ofthe electric wires 12.

The fastening components 50 are components for fastening the electricwires 12 to a mounting object 70 such as a car body panel or a rodcomponent. Here, the fastening components 50 are also sewn on thefunctional exterior component 30. The fastening components 50 arecomponents referred to as clamps or clips, and each include a pillarpart 54 and a wing part 56 extending from the tip of the pillar part 54.

The fastening components 50 have, for example, holes 52 or depressionsthrough which the fastening components 50 are sewn on the functionalexterior component 30. The holes 52 or the depressions may be existingcomponents or new dedicated components.

In the example illustrated in FIG. 2, the fastening components 50 areattached to protrude on the one main surface 31 a on which the electricwires 12 are disposed. The fastening components 50 enable the electricwires 12 to abut the mounting object 70, and can radiate the heat of theelectric wires 12 through the mounting object 70. When the mountingobject 70 is a component capable of protecting the electric wires 12,the mounting object 70 can protect one side of the electric wires 12,whereas the functional exterior component 30 can protect the other sideof the electric wires 12. The fastening components 50 may be attached toprotrude on the other main surface 31 b.

[Manufacturing Method]

Next, a method for manufacturing the wire harness 10 according toEmbodiment 1 will be described with reference to FIGS. 3 to 6. FIGS. 3to 6 illustrate steps for manufacturing the wire harness 10 according toEmbodiment 1.

First, the functional exterior component 30, the electric wire 12, thethread 40, and a needle 80 are prepared. Here, the needle 80 with an eye82 is used. The eye 82 is provided at the tip of the needle 80. Thethread 40 is threaded through the eye 82 as an upper thread 84.

Next as illustrated in FIG. 3, the needle 80 having the eye 82 throughwhich the upper thread 84 is threaded is inserted into the functionalexterior component 30 from the other main surface 31 b (a step (a)).Consequently, a part of the upper thread 84 passes through the one mainsurface 31 a together with the needle 80.

Next, the loop 85 is formed from the upper thread 84 that has passedthrough the one main surface 31 a (a step (b)). For example, when theneedle 80 is restored to the other main surface 31 b as illustrated inFIG. 4, a part of the upper thread 84 that has passed through the onemain surface 31 a together with the needle 80 remains on the one mainsurface 31 a to form the loop 85.

Next, the electric wire 12 functioning as a lower thread 86 is threadedthrough the loop 85 (a step (c)). First, the loop 85 is widened asillustrated in FIG. 5. Then, the loop 85 is rotated around a bobbin 90that houses the wound lower thread 86 to allow the bobbin 90 to passthrough the loop 85.

Then, the loop 85 is tightened to thread the lower thread 86 through theloop 85 as illustrated in FIG. 6. This completes the sewing of theelectric wire 12 in the portion.

Repeating the same operations while the functional exterior component 30is being conveyed enables the one electric wire 12 to be seamlessly sewnwith the single thread 40.

Then, the connectors 20 and the fastening components 50 are additionallysewn on the exterior component 30 on which the electric wires 12 havebeen sewn. These may be sewn before the electric wires 12 are sewn.After the connectors 20 and the electric wires 12 are sewn, the ends ofthe electric wires 12 are connected to the insulation-displacementconnectors 20. Consequently, the wire harness 10 is completed.

The sewing step in the manufacturing method may be performed by a sewingmachine or by hand. Application of the sewing machine can automate partof the step.

When the sewing machine is used, a known rotary hook part in the sewingmachine performs an operation of rotating the loop 85 around the bobbin90 while widening the loop 85. Loosening the upper thread 84 more thanthe lower thread 86 can prevent the electric wire 12 functioning as thelower thread 86 from being pulled by the upper thread 84 toward theother main surface 31 b of the functional exterior component 30.

According to the wire harness 10 structured as above and themanufacturing method thereof, the electric wires 12 are sewn on thefunctional exterior component 30 with the threads 40. This structure canbe applied in common to the various functional exterior components 30upon attachment to the electric wires 12. Since a sewing machine isavailable in the sewing step, the wire harness 10 can be easilymanufactured.

Since the functional exterior component 30 has abrasion resistance, theelectric wires 12 can be easily protected.

Since the fastening components 50 for fastening the electric wires 12 tothe mounting object are also sewn on the functional exterior component30, the fastening components 50 can be easily attached.

Since the connectors 20 provided at the ends of the electric wires 12are also sewn on the functional exterior component 30, the connectors 20can be easily positioned.

Embodiment 2

Next, a wire harness 110 according to Embodiment 2 will be described.FIG. 7 illustrates a schematic perspective view of the wire harness 110according to Embodiment 4. In the following description of eachEmbodiment, the same reference numerals are assigned to the sameconstituent elements described above, and the description thereof willbe omitted.

The wire harness 110 according to Embodiment 2 differs from the wireharness 10 according to Embodiment 1 in that a functional exteriorcomponent 130 is a shielding component having shielding properties.

The shielding component is formed from, for example, a metal foil, ametal mesh, a laminated component of a metal foil and a resin sheet, ora sheet material made of a conductive resin. The metal foil may beapplied when the needle 80 can penetrate the shielding component usingthe metal foil. When, for example, the metal mesh is used, the needle 80may be inserted into the holes provided in the mesh or penetrate a metalportion of the mesh. Here, the shielding component is flexible to theextent that it can be wound around the electric wires 12. The shieldingcomponent covers the surrounding of the electric wires 12 with theelectric wires 12 sewn on the shielding component. This enables theshielding component to shield the electric wires 12 inside. Theshielding component has fixed pieces 132 each with a screw hole 134. Theshielding component is grounded with the fixed pieces 132 being fixedto, for example, a car body panel with bolts. The grounding method mayinclude withdrawing a drain line abutting the shielding component orapplying a part of the electric wires 12 sewn on the shielding componentas a drain line.

The electric wires 12 can be easily shielded in the wire harness 110with such a structure.

Embodiment 3

Next, a wire harness 210 according to Embodiment 3 will be described.FIG. 8 illustrates a partial enlarged plan view of the wire harness 210according to Embodiment 3.

The wire harness 210 according to Embodiment 3 differs from the wireharness 10 according to Embodiment 1 in that a functional exteriorcomponent 230 is a tension member subjected to the tensile force appliedto the electric wires 12.

For example, a sheet material that is less stretchable than the electricwires 12 will be used as the functional exterior component 230, and thepart of the electric wires 12 sewn on the functional exterior component230 will slack as illustrated in FIG. 8. The electric wires 12 willslack, for example, in a portion between adjacent seams. This enablesthe functional exterior component 230 to be subjected to the tensileforce applied to the wire harness 210 along the extension direction ofthe electric wires 12. Consequently, it is possible to prevent theexcessive tensile force from being applied to the electric wires 12.

The electric wires 12 are hardly damaged even with application of thetensile force to the wire harness 210 with such a structure.

Embodiment 4

Next, a wire harness 310 according to Embodiment 4 will be described.FIG. 9 illustrates a schematic cross-sectional view of the wire harness310 according to Embodiment 2. Note that FIG. 9 is a cross-sectionalview of the wire harness 310 cut in a plane orthogonal to the extensiondirection of the electric wires 12.

The wire harness 310 according to Embodiment 4 differs from the wireharness 10 according to Embodiment 1 in that a functional exteriorcomponent 330 is a waterproof sheet with waterproof properties.

The waterproof sheet is, for example, a polyethylene sheet. Thewaterproof sheet is flexible to the extent that it can be wound aroundthe electric wires 12. The waterproof sheet covers the electric wires 12and the surrounding of the seam portions, with the electric wires 12sewn on the waterproof sheet. This prevents, for example, water fromentering the inside of the waterproof sheet. The winding end portion ofthe waterproof sheet may be fixed by, for example, an adhesive tape oran adhesive without having any gap. It is not necessary that thewaterproof sheet covers the electric wires 12 and the surrounding of theseam portions. The waterproof properties can be enhanced by filling seamholes of the waterproof sheet with a water sealant.

The electric wires 12 can be easily waterproofed in the wire harness 310with such a structure.

Embodiment 5

Next, a wire harness 410 according to Embodiment 5 will be described.FIG. 10 illustrates a schematic cross-sectional view of the wire harness410 according to Embodiment 5.

The wire harness 410 according to Embodiment 5 differs from the wireharness 10 according to Embodiment 1 in that a functional exteriorcomponent 430 is wound around the electric wires 12 and a fasteningcomponent 450 maintains the winding state.

In the functional exterior component 430, a through hole 432 into whicha fastening portion of the fastening component 450 can be inserted maybe formed in a portion overlapping a portion in which the fasteningcomponent 450 is provided.

The winding state of the functional exterior component 430 can be easilymaintained in the wire harness 410 with such a structure.

Embodiment 6

Next, a wire harness 510 according to Embodiment 6 will be described.FIG. 11 is a schematic plan view of the wire harness 510 according toEmbodiment 6. FIG. 12 illustrates a schematic cross-sectional view ofthe wire harness 510 cut along an XII-XII line in FIG. 11. FIG. 13illustrates steps for manufacturing the wire harness according toEmbodiment 6.

The wire harness 510 according to Embodiment 6 differs from the wireharness 10 according to Embodiment 1 in how to sew the electric wire 12.

Specifically, in the wire harness 10 according to Embodiment 1, theelectric wire 12 is sewn with the single thread 40. The electric wire 12is sewn as the lower thread 86 that is a machine sewing thread.

In contrast, in the wire harness 510 according to Embodiment 6, theelectric wire 12 is sewn with threads 540 including an upper thread 584and a lower thread 586. Thus, the upper thread 584 and the lower thread586 that are machine sewing threads are provided separately from theelectric wire 12. The electric wire 12 is sewn on the functionalexterior component 30 with the upper thread 584 and the lower thread 586as the threads 540.

The upper thread 584 and the lower thread 586 are sewn into thefunctional exterior component 30 with staggered (zig-zagged) stitches.The electric wire 12 is disposed between seams S that are mutuallydistant in a horizontal direction to be sandwiched between thefunctional exterior component 30 and one of the upper thread 584 and thelower thread 586.

A method for manufacturing such a wire harness will include thefollowing steps (a) and (b).

The step (a) is a step of disposing the electric wire 12 on the one mainsurface 31 a of the functional exterior component 30. For example, aguiding component 594 guides the electric wire 12 wound and housed in abobbin 592 to the one main surface 31 a of the functional exteriorcomponent 30 as illustrated in FIG. 13. For example, a known guidingcomponent for guiding a strap to a surface of an object to be sewn canbe used as the guiding component 594 in an embroidery sewing machine.

The step (b) is a step of sewing the upper thread 584 and the lowerthread 586 on the functional exterior component 30 while the electricwire 12 is sandwiched between one of the upper thread 584 and the lowerthread 586 and the one main surface 31 a of the functional exteriorcomponent 30. The upper thread 584 and the lower thread 586 are sewnwith staggered stitches with the electric wire 12 guided to the one mainsurface 31 a of the functional exterior component 30 by the guidingcomponent 594, while the electric wire 12, the functional exteriorcomponent 30, and the sewing machine body including the needle 80 arerelatively moved in a conveying direction and the horizontal direction.

Since the electric wire 12 does not have to be used as the upper thread584 or the lower thread 586 according to this aspect, the electric wire12 with difficulties in being applied as the upper thread 584 or thelower thread 586, for example, a thick wire such as a power line can beeasily sewn.

Since the bobbin 592 for winding and housing the electric wire 12 doesnot need to pass through any loop, the bobbin 592 can be upsized. Theelectric wire 12 to be sewn can be easily elongated.

When the upper thread 584 and the lower thread 586 are providedseparately from the electric wire 12 and the electric wire 12 can besewn on the functional exterior component 30 with the upper thread 584and the lower thread 586, how to sew with the upper thread 584 and thelower thread 586 is not limited to the staggered stitches. For example,an upper thread 584A and a lower thread 586A may be sewn as a wireharness 510A according to a modification illustrated in FIGS. 14 and 15.

Specifically, the wire harness 510A according to the modification hasseams S in an area of the functional exterior component 30 that overlapsthe electric wire 12. At least one of portions between the adjacentseams S in one of the upper thread 584A and the lower thread 586A (theupper thread 584A in the example illustrated in FIGS. 14 and 15) iswound around the electric wire. To perform such a sewing method, theelectric wire 12 or the guiding component 594 for guiding the electricwire 12 may be staggered horizontally opposite to the needle 80 whenseams S1 and S2 are formed. Since the other of the upper thread 584A andthe lower thread 586A (the lower thread 586A in the example illustratedin FIGS. 14 and 15) is not wound around the electric wire 12, the otherone extends parallel to the electric wire 12.

Since a thread for pressing the electric wire 12 (the upper thread 584Ahere) can be wound around an area half the electric wire 12 or more,particularly, an area close to a full circle in the wire harness 510A,the electric wire 12 is hardly displaced from the functional exteriorcomponent 30 in the horizontal direction. Since a gap is hardly formedbetween the thread for pressing the electric wire 12 (the upper thread584A here), the electric wire 12, and the functional exterior component30, the thread for pressing the electric wire 12 (the upper thread 584Ahere) is hardly caught by the surrounding components.

[Modifications]

Although Embodiment 1 describes that the protective sheet has abrasionresistance, this is not necessary. The protective sheet may havepenetration resistance. Here, the protective sheet has only to havepenetration resistance required under a use environment of a vehicle.The needle 80 to be used when the electric wire 12 is sewn on theprotective sheet may be inserted into the protective sheet with thepenetration force higher than the penetration resistance.

Although Embodiment 1 describes that the functional exterior component30 is a protective sheet, this is not necessary. The functional exteriorcomponent 30 may be a soundproof sheet (soundproof component). Thesoundproof sheet is, for example, a sheet component made of a nonwovenfabric or a foamed resin. When the functional exterior component 30 is asoundproof sheet, a structure for enclosing the electric wires 12 sewnon the functional exterior component 30 with the soundproof sheet ispossible. This can improve the soundproofing properties. The soundproofsheet may be folded to enclose the electric wires 12, or a soundproofsheet on which the electric wires 12 are sewn and a soundproof sheetseparately provided from the former soundproof sheet may sandwich theelectric wires 12.

Although Embodiment 2 describes that the functional exterior component130 is made of a metal, the functional exterior component 130 made of ametal may be used not as a shielding component but as a heat radiatingcomponent. When the functional exterior component 130 is used as a heatradiating component, the functional exterior component 130 and theelectric wire 12 abutting at least in a part of an area, and at least apart of an area of the functional exterior component 130 exposed outsideare probable.

When the functional exterior component 130 is used as a heat radiatingcomponent, metals are generally superior in thermal conductivity butoften inferior in emission ratio (may be referred to as emissivity).Thus, high emission ratio portions 138 may be formed on the surfaces ofthe functional exterior component 130 as illustrated in FIG. 16. Thehigh emission ratio portions 138 are portions with the emission ratiohigher than that of an inner portion 137.

According to Wien's displacement law, the peak wavelength of lightemitted from an object through thermal radiation is inverselyproportional to the temperature of the object. It is also known that thesame material may have different values of the emission ratios,depending on the temperature of the object (wavelength of light). Sinceit is desired to increase the emission ratio of the wire harness 110 tobe mounted on a vehicle, the high emission ratio portions 138 may have ahigher emission ratio to correspond to the peak wavelength in a hightemperature zone generated in a use environment of the vehicle.

A surface treatment for increasing the emission ratio is applied to thesurfaces of the functional exterior component 130 to form the highemission ratio portions 138. The high emission ratio portions 138 willbe, for example, oxide films formed by oxidizing the metal surfaces ofthe inner portion 137. The high emission ratio portions 138 may be, forexample, plated portions or painted portions subjected to a platingprocess or a painting process, respectively, on the surface of acomponent which forms the inner portion 137. The paint to be used in thepainting process may be, for example, a resin.

Although the high emission ratio portions 138 are formed on both of themain surfaces of the functional exterior component 130 in the exampleillustrated in FIG. 16, the high emission ratio portion 138 may beformed only on one of the main surfaces thereof. When the high emissionratio portion 138 is formed only on one of the main surfaces of thefunctional exterior component 130, it may be formed on the main surfaceon which the electric wires 12 are disposed or on the opposite mainsurface thereof. The high emission ratio portion 138 may be formed overthe entire area of the main surface of the functional exterior component130 or only on a part of the area thereof. When the high emission ratioportion 138 is formed only on a part of the area of the main surface ofthe functional exterior component 130, it may be or may not be formed ona portion on which the electric wires 12 are disposed. The high emissionratio portion 138 may be preferably formed on an outward plane of thefunctional exterior component 130. When the high emission ratio portion138 is formed on a portion of the functional exterior component 130where heat dissipation cannot be expected from conduction or convectionwith the wire harness 110 being mounted on a vehicle, the high emissionratio portion 138 is more effective at dissipating heat from theportion.

Formation of the high emission ratio portion enables more efficient heatradiation. Since the temperature rise in the electric wires 12 can besuppressed lower, the electric wires 12 can be downsized. Since thenecessary amount of heat storage can be reduced as the amount of heatradiation in the functional exterior component 130 increases, thefunctional exterior component 130 can be thinned.

The functional exterior component 30 may have different tensilestrengths in the first and second directions that are orthogonal to eachother, among the spreading directions of the main surface of thefunctional exterior component 30. The direction with a higher tensilestrength is preferably equal to the extension direction of the electricwires 12 in the functional exterior component 30. This is because whenthe wire harness 10 is mounted on a vehicle, the functional exteriorcomponent 30 may be pulled toward the extension direction of theelectric wires 12 more than being pulled toward the direction orthogonalto the extension direction of the electric wires 12, and the tensileforce of the former pulling may be higher than that of the latterpulling. Since particularly, making the direction with a higher tensilestrength equal to the extension direction of the electric wires 12enables the wire harness 10 to be hardly damaged even when the wireharness 10 is strongly pulled toward the extension direction, the wireharness 10 is easily mounted on the vehicle. For example, the functionalexterior component 30 with such anisotropy in the tensile strength issuitable as the functional exterior component 230 according toEmbodiment 3 to be used as a tension member.

The functional exterior component 30 may be any as long as the tensilestrengths in the first and second directions are different. The materialand the manufacturing method, etc. do not matter. For example, thefunctional exterior component 30 with the different tensile strengths inthe first and second directions may be obtained by drawing, duringmanufacture, a sheet material formed by extrusion molding, such as auniaxially oriented film or a biaxially oriented film. Filament nonwovenfabrics such as spunlaid nonwovens normally have a high tensile strengthin a fiber elongation direction.

As illustrated in FIG. 17, the functional exterior component 30 mayhave, for example, an additional shape with the different tensilestrengths in the first and second directions. In the example of afunctional exterior component 630 illustrated in FIG. 17, altering theshape of compressed portions 638 yields the different tensile strengths.Specifically, the functional exterior component 630 subjected to thecompression processing such as embossing includes the compressedportions 638 that are more compressed than a surrounding portion 637.Here, the compressed portions 638 are each formed with longer sides,such as rectangles or ovals. In the functional exterior component 630,the tensile strength of the compressed portions 638 along the long-sidedirection will be higher than the tensile strength of the compressedportions 638 along the short-side direction.

In the example illustrated in FIG. 17, a plurality of the compressedportions 638 are formed in alignment in the vertical and horizontaldirections on the plane of the paper. In each of the directions, theplurality of the compressed portions 638 are oriented toward the samedirection. Specifically, the plurality of the compressed portions 638are aligned so that the short-side direction is equal to the verticaldirection on the plane of the paper. The plurality of the compressedportions 638 are also aligned so that the long-side direction is equalto the horizontal direction on the plane of the paper. Here, thefunctional exterior component 630 may have the compressed portions 638at least in a position of an intermediate portion along the horizontaldirection on the plane of the paper, in any position along thehorizontal direction on the plane of the paper as illustrated in FIG.17, and at least in a part of an area along the vertical direction onthe plane of the paper in that position. This is because if thecompressed portions 638 are not formed in the position of theintermediate portion of the functional exterior component 630 along thehorizontal direction on the plane of the paper and along the verticaldirection on the plane of the paper in that position, the stress mayconcentrate on the intermediate portion with application of the tensileforce to the functional exterior component 630 in the horizontaldirection on the plane of the paper.

The functional exterior component 30 may have different stretchabilitiesin the first and second directions. When the electric wires 12 aredisposed to linearly extend in a portion on which the functionalexterior component 30 is attached, the direction in which the functionalexterior component 30 is less stretchable is preferably equal to theextension direction of the electric wires 12. This makes it easier tomaintain the electric wires 12 linearly extended. The proportion of thefunctional exterior component 30 for bearing the load of a part of thetensile force applied to the electric wires 12 increases as the electricwires 12 are less stretchable. Thus, it is possible to expect anadvantage of the functional exterior component 30 functioning as atension member. Since the electric wires 12 can be wound in a directionin which the functional exterior component 30 is more stretchable whenthe functional exterior component 30 is wound around the electric wires12 or when the functional exterior component 30 is wound around a rodcomponent for reinforcement with the electric wires 12 laid along therod component, the electric wires 12 are easily wound.

When the electric wires 12 are disposed to extend with a bend in aportion on which the functional exterior component 30 is attached, thedirection in which the functional exterior component 30 is morestretchable is preferably equal to the extension direction of theelectric wires 12. This allows the functional exterior component 30 tofollow the bend of the electric wires 12.

The functional exterior component 30 may be any as long as thestretchabilities in the first and second directions are different. Thematerial and the manufacturing method, etc. do not matter. For example,the functional exterior component 30 with the different stretchabilitiesin the first and second directions may be obtained by drawing, duringmanufacture, a sheet material formed by extrusion molding, such as auniaxially oriented film or a biaxially oriented film. Filament nonwovenfabrics such as spunlaid nonwovens are normally more stretchable in adirection intersecting with a fiber elongation direction.

The functional exterior component 30 may, for example, have anadditional shape with the different stretchabilities in the first andsecond directions. In the example of the functional exterior component630 illustrated in FIG. 17, the compressed portions 638 with theaforementioned shape in the vertical direction on the plane of the paperwill be more stretchable than that in the horizontal direction on theplane of the paper.

In the first and second directions, the direction with a higher tensilestrength may be equal to or different from the direction with lessstretchability. In the first and second directions, different tensilestrengths with the same stretchability, or the same tensile strengthwith different stretchabilities may be exhibited.

Although sewing each of the electric wires 12 with the thread 40 isdescribed above, this is not necessary. A plurality of the electricwires 12 may be collectively sewn with the thread 40. Here, theplurality of the electric wires 12 may be bundled by, for example, anadhesive tape. A cable including the plurality of the electric wires 12and a sheath covering the surrounding of the plurality of the electricwires 12 may be used.

As illustrated in FIG. 18, the plurality of the electric wires 12 may besewn with a same thread 540B while being parallel to each other.Although no seam S is formed between the electric wires 12 in theexample illustrated in FIG. 18, the seam S may be formed between theelectric wires 12. Consequently, the electric wires 12 are hardlydisplaced in the horizontal direction.

Although application of the insulation-displacement connectors 20 as theconnectors 20 is described above, this is not necessary. The connectorsmay, for example, house crimp contacts crimped onto the ends of theelectric wires 12.

The structures described in Embodiments and modifications thereof can beappropriately combined as long as they are not contradictory. Forexample, a functional exterior component may be a combination of aplurality of sheet materials with different functions.

Although this invention is described in detail, the foregoingdescription is in all aspects illustrative and does not restrict theinvention. It is therefore understood that numerous modifications andvariations can be devised without departing from the scope of theinvention.

EXPLANATION OF REFERENCE SIGNS

-   10 wire harness-   12 electric wire-   14 core wire-   16 insulating coating-   20 connector-   21 connector housing-   22 hole-   23 first component-   24 second component-   26 insulation-displacement contact-   27 insulation-displacement part-   30 functional exterior component-   31 a main surface-   31 b another main surface-   40 thread-   50 fastening component-   52 hole-   54 pillar part-   56 wing part-   70 mounting object-   80 needle-   82 eye-   84 upper thread-   85 loop-   86 lower thread-   90 bobbin

1. A wire harness, comprising: a functional exterior component shapedinto a sheet; at least one electric wire disposed on one main surface ofthe functional exterior component; and at least one thread for sewingthe electric wire on the functional exterior component.
 2. The wireharness according to claim 1, wherein the functional exterior componentincludes a soundproof component with soundproofing properties.
 3. Thewire harness according to claim 1, wherein the functional exteriorcomponent includes a shielding component capable of shielding theelectric wire.
 4. The wire harness according to claim 1, wherein thefunctional exterior component includes a protective component capable ofprotecting the electric wire from abrasion, the protective componenthaving abrasion resistance.
 5. The wire harness according to claim 1,wherein the functional exterior component includes a heat radiatingcomponent capable of radiating heat of the electric wire.
 6. The wireharness according to claim 5, wherein a high emission ratio portion isformed on a surface of the heat radiating component, the high emissionratio portion being higher in emission ratio than an inner portion ofthe heat radiating component.
 7. The wire harness according to claim 1,wherein the functional exterior component functions as a tension membersubjected to a tensile force applied to the electric wire.
 8. The wireharness according to claim 1, wherein in the functional exteriorcomponent, a tensile strength in a direction along an extensiondirection of the electric wire is higher than a tensile force in adirection orthogonal to the direction.
 9. The wire harness according toclaim 1, wherein the functional exterior component is water-proofed, andcovers the electric wire and a portion on which the electric wire issewn.
 10. The wire harness according to claim 1, wherein a connectorprovided at an end of the electric wire is sewn on the functionalexterior component.
 11. The wire harness according to claim 1, wherein afastening component for fastening the electric wire to a mounting objectis sewn on the functional exterior component.
 12. The wire harnessaccording to claim 1, wherein the electric wire is sewn with the threadthat is a single thread.
 13. The wire harness according to claim 1,wherein the electric wire is sewn with the at least one thread includingan upper thread and a lower thread.
 14. A method for manufacturing thewire harness according to claim 12, the method comprising: (a) insertinga needle into the functional exterior component from another mainsurface of the functional exterior component, the needle having an eyethrough which the thread passes as an upper thread; (b) forming a loopfrom the upper thread that has passed through the one main surface; and(c) threading the electric wire through the loop as a lower thread. 15.A method for manufacturing the wire harness according to claim 13, themethod comprising: (a) disposing the electric wire on the one mainsurface of the functional exterior component; and (b) sewing theelectric wire with the upper thread and the lower thread on thefunctional exterior component with the electric wire being sandwichedbetween one of the upper thread and the lower thread and the one mainsurface of the functional exterior component.